Systems and methods for the construction of structures

ABSTRACT

Construction systems for constructing a structure on a foundation and methods relating thereto are disclosed. In an embodiment, the construction system includes a rail assembly configured to be mounted to the foundation. In addition, the construction system includes a gantry movably disposed on the rail assembly configured to translate along a first axis relative to the rail assembly. Further, the construction system includes a printing assembly movably disposed on the gantry and configured to translate along a second axis relative to the gantry. The second axis is orthogonal to the first axis. The printing assembly is configured to deposit vertically stacked layers of an extrudable building material on the foundation to construct the structure. The gantry has a width along the second axis that is configured to be adjusted relative to the foundation.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of pending patent applicationSer. No. 16/294,714, filed Mar. 6, 2019, from which priority is claimed.The contents of this application are hereby incorporated by reference intheir entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

This disclosure is generally directed to the construction of structures(e.g., dwellings, buildings, etc.). More particular, this disclosure isdirected to the construction of structures utilizing additivemanufacturing techniques.

Structures (e.g., dwellings, buildings, sheds, etc.) may be manufacturedwith a multitude of different materials and construction methods. Amongthe materials commonly used in the construction of structures isconcrete. For example, concrete may be used to form the foundation aswell as the exterior walls of a structure.

BRIEF SUMMARY

Some embodiments disclosed herein are directed to a construction systemfor constructing a structure on a foundation. In an embodiment, theconstruction system includes a rail assembly configured to be mounted tothe foundation. In addition, the construction system includes a gantrymovably disposed on the rail assembly configured to translate along afirst axis relative to the rail assembly. Further, the constructionsystem includes a printing assembly movably disposed on the gantry andconfigured to translate along a second axis relative to the gantry. Thesecond axis is orthogonal to the first axis. The printing assembly isconfigured to deposit vertically stacked layers of an extrudablebuilding material on the foundation to construct the structure. Thegantry has a width along the second axis that is configured to beadjusted relative to the foundation.

Other embodiments disclosed herein are directed to a method ofconstructing a structure. In an embodiment, the method includes (a)adjusting a width of a gantry. The gantry includes a first verticalsupport assembly, a second vertical support assembly, a trolley bridgeassembly coupled to and extending between the first and second verticalsupport assemblies, and a printing assembly movably coupled to thetrolley bridge assembly. The width extends between the first and secondvertical support assemblies. In addition, the method includes (b)engaging the first and second vertical support assemblies with a pair ofrail assemblies mounted to opposing sides of a foundation, and (c)translating the first and second vertical support assemblies along afirst axis relative to the pair of rail assemblies. Further, the methodincludes (d) translating the printing assembly along a second axis thatis orthogonal to the first axis relative to the trolley bridge assembly.Still further, the method includes (e) extruding an extrudable buildingmaterial from the printing assembly during (c) and (d).

Embodiments described herein comprise a combination of features andcharacteristics intended to address various shortcomings associated withcertain prior devices, systems, and methods. The foregoing has outlinedrather broadly the features and technical characteristics of thedisclosed embodiments in order that the detailed description thatfollows may be better understood. The various characteristics andfeatures described above, as well as others, will be readily apparent tothose skilled in the art upon reading the following detaileddescription, and by referring to the accompanying drawings. It should beappreciated that the conception and the specific embodiments disclosedmay be readily utilized as a basis for modifying or designing otherstructures for carrying out the same purposes as the disclosedembodiments. It should also be realized that such equivalentconstructions do not depart from the spirit and scope of the principlesdisclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of various exemplary embodiments, referencewill now be made to the accompanying drawings in which:

FIG. 1 is a front view of a construction system according to someembodiments disclosed herein;

FIG. 2 is a schematic top view of the construction system of FIG. 1;

FIG. 3 is a perspective view of the gantry of the construction system ofFIG. 1;

FIGS. 4 and 5 are perspective views of one of the rail segments of therail assemblies of the construction system of FIG. 1;

FIG. 6 is an enlarged front view of one of the vertical supportassemblies of the gantry of FIG. 3 engaged with one of the railassemblies of the construction system of FIG. 1;

FIG. 7 is an enlarged bottom view of a gear coupled to the verticalsupport assembly of FIG. 6 engaged with a rack mounted to the railassembly of FIG. 6;

FIG. 8 is an enlarged front view of another vertical support assemblyfor use within the gantry of FIG. 3 according to some embodimentsdisclosed herein;

FIG. 9 is a perspective view of one of the lateral adjustment assembliesfor an upper bridge assembly of the gantry of FIG. 3;

FIG. 10 is a front view of the lateral adjustment assembly of FIG. 9;

FIG. 11 is a back view of the lateral adjustment assembly of FIG. 9;

FIG. 12 is a side view of the lateral adjustment assembly of FIG. 9;

FIG. 13 is an enlarged side view of one of the locking clamps of thelateral adjustment assembly of FIG. 9;

FIG. 14 is another front view of the lateral adjustment assembly of FIG.9 with one of the plates removed;

FIG. 15 is a back view of the first vertical adjustment assembly for thetrolley bridge assembly of the gantry of FIG. 3;

FIG. 16 is an enlarged side view of one of the vertical supportassemblies of the gantry of FIG. 3;

FIG. 17 is a front view of the second vertical adjustment assembly forthe trolley bridge assembly of the gantry of FIG. 3;

FIG. 18 is a rear view of the second vertical adjustment assembly ofFIG. 17;

FIG. 19 is a side view of the second vertical adjustment assembly ofFIG. 17;

FIG. 20 is a perspective view of the printing assembly of theconstruction system of FIG. 1;

FIG. 21 is a rear view of the printing assembly of FIG. 20;

FIG. 22 is a side view of the printing assembly of FIG. 20;

FIG. 23 is a block diagram of the construction system of FIG. 1;

FIG. 24 is a flow chart of a method for printing a structure accordingto some embodiments disclosed herein;

FIGS. 25-27 are sequential, perspective views of an example constructionoperations utilizing the construction system of FIG. 1 according to someembodiments;

FIGS. 28 and 29 are perspective views of a material delivery system foruse with a construction system according to some embodiments disclosedherein;

FIG. 30 is a block diagram of the material delivery system of FIGS. 28and 29; and

FIG. 31 is a flow chart of a method for mixing and delivering anextrudable building material with the material delivery system of FIGS.28 and 29.

DETAILED DESCRIPTION

The following discussion is directed to various exemplary embodiments.However, one of ordinary skill in the art will understand that theexamples disclosed herein have broad application, and that thediscussion of any embodiment is meant only to be exemplary of thatembodiment, and not intended to suggest that the scope of thedisclosure, including the claims, is limited to that embodiment.

The drawing figures are not necessarily to scale. Certain features andcomponents herein may be shown exaggerated in scale or in somewhatschematic form and some details of conventional elements may not beshown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and“comprising” are used in an open-ended fashion, and thus should beinterpreted to mean “including, but not limited to . . . .” Also, theterm “couple” or “couples” is intended to mean either an indirect ordirect connection. Thus, if a first device couples to a second device,that connection may be through a direct connection of the two devices,or through an indirect connection that is established via other devices,components, nodes, and connections. In addition, as used herein, theterms “axial” and “axially” generally mean along or parallel to a givenaxis (e.g., central axis of a body or a port), while the terms “radial”and “radially” generally mean perpendicular to the given axis. Forinstance, an axial distance refers to a distance measured along orparallel to the axis, and a radial distance means a distance measuredperpendicular to the axis.

As used herein, the terms “about,” “approximately,” substantially,”“generally,” and the like mean plus or minus 10% of the stated value orrange. In addition, as used herein, an “extrudable building material”refers to a building material that may be delivered or conveyed througha conduit (e.g., such as a flexible conduit) and extruded (e.g., via anozzle or pipe) in a desired location. In some embodiments, anextrudable building material includes a cement mixture (e.g., concrete,cement, etc.). Further, as used herein, the term “computing device”refers to any suitable device (or collection of devices) that isconfigured to execute, store, and/or generate machine readableinstructions (e.g., non-transitory machine readable medium). The termmay specifically include devices, such as, computers (e.g., personalcomputers, laptop computers, tablet computers, smartphones, personaldata assistants, etc.), servers, controllers, etc. A computing devicemay include a processor and a memory, wherein the processor is toexecute machine readable instructions that are stored on the memory.

As previously described above, structures (e.g., dwellings, buildings,sheds, etc.) may be manufactured with a multitude of different materialsand construction methods. Traditionally, a building (e.g., a dwelling)may be constructed upon a composite slab or foundation that comprisesconcrete reinforced with re-bar or other metallic materials. Thestructure itself may then be framed (e.g., with wood and/or metalframing members), and then an outer shell and interior coverings (e.g.,ply-wood, sheet rock, etc.) may be constructed around the structuralframing. Utilities (e.g., water and electrical power delivery as well asvents and ducting for air conditioning and heating systems) may beenclosed within the outer shell and interior covers along withinsulation. This method of designing and constructing a structure iswell known and has been successfully utilized in constructing anuncountable number of structures; however, it requires multipleconstructions steps that may not typically be performed simultaneouslyand that often require different skills and trades to complete. As aresult, this process for constructing a structure can extend over aconsiderable period (e.g., 6 months to a year or more). Such a lengthyconstruction period is not desirable in circumstances that call for theconstruction of a structure or multiple structures in a relatively shortperiod of time.

Accordingly, embodiments disclosed herein include construction systemsand methods of construction that allow a structure (such as a personaldwelling) to be constructed in a fraction of the time associated withtraditional construction methods. In particular, embodiments disclosedherein utilize additive manufacturing techniques (e.g., threedimensional (3D) printing) in order to produce a structure more quicklyand economically in a systematic manner.

Referring now to FIGS. 1 and 2, a construction system 10 according tosome embodiments is shown. In this embodiment, construction system 10generally includes a pair of rail assemblies 20, a gantry 50 movablydisposed on rail assemblies 20, and a printing assembly 150 movablydisposed on gantry 50. As will be described below, construction system10 is configured to form a structure 5 (such as for example a personaldwelling) via additive manufacturing, specifically 3D printing, on afoundation 4. In particular, construction system 10 (via rail assemblies20 and gantry 50) is configured to controllably move or actuate printingassembly 150 relative to the foundation 4 along each of a plurality oforthogonal movement axes or directions 12, 14, 16 such that printingassembly 150 may controllably deposit an extrudable building material ina plurality of vertically stacked layers 5 a to form structure 5. Asshown in FIG. 2, axes 12, 14, 16 are each orthogonal to one another—withaxis 12 being orthogonal to both axes 14, 16, axis 14 being orthogonalto axes 12 and 16, and axis 16 being orthogonal to axes 12 and 14.

Referring now to FIGS. 1, 2, 4, and 5, in this embodiment, each railassembly 20 is disposed on a perimeter or side surface 6 of foundation 4(see FIG. 1) and includes a central axis 25, a first end 20 a, and asecond end 20 b opposite first end 20 a. Axes 25 of rail assemblies 20are parallel and radially spaced from one another such that first ends20 a and second ends 20 b of rail assemblies 20 are generally alignedwith one another across foundation 4. In addition, each of the axes 25of rail assemblies 20 extends parallel to axis 12 (and thus, each axis25 also extends in a direction that is perpendicular to the direction ofaxis 14 and the direction of axis 16).

As best shown in FIGS. 2 and 4-5, each rail assembly 20 includes aplurality of rail segments 21 coupled end-to-end along the correspondingaxis 25. Each rail segment 21 includes a first end 21 a and a second end21 b opposite first end 21 a. Within each rail assembly 20, an end 21 a,21 b of one of the corresponding rail segments 21 is coincident with thefirst end 20 a and another end 21 a, 21 b of another of thecorresponding rail segments 21 is coincident with the second end 20 b.More particular, each rail segment 21 includes a first elongate anglemember 22, a second elongate angle member 24, and an elongate cable tray30, wherein each of the angles member 22, 24, and cable tray 30 extendaxially between ends 21 a, 21 b along axis 25. First angle member 22includes a first portion 22 a and a second portion 22 b extendingperpendicularly from first portion 22 a. First portion 22 a includes aplurality of apertures 23 extending therethrough. In this embodiment,apertures 23 are slots that are elongated axially with respect to axis25. As shown in FIG. 5, angle member 22 is secured to foundation 4 byinserting bolts 21 or other suitable connection members through theapertures 23 and into perimeter 6 of foundation 4. Accordingly, once thefirst elongate angle members 22 of rail assemblies 20 are secured toperimeter 6 of foundation 4, second portions 22 b of angle members 22extend parallel to and may be flush with top surface 4 a of foundation4.

Referring again to FIGS. 3 and 4, second elongate angle member 24includes a first portion 24 a, and a second portion 24 b extendingperpendicularly to the first portion 24 a. First portion 24 a extendsparallel to second portion 22 b of the corresponding first angle member22 and is secured thereto via any suitable method (e.g., bolts, rivets,welding, etc.). An axially extending elongate angle member 28 is secured(e.g., welded, bolted, riveted, etc.) to first portion 24 a of secondangle member 24. As will be described in more detail below, anglemembers 28 of rail segments 21 align within each rail assembly 20 toform tracks to guide movement of gantry 50 (and printing assembly 150)across foundation 4 along axis 12 during construction operations. Inaddition, an elongate rack 32 is secured to second portion 24 b of eachsecond angle member 24. Accordingly, the rack 32 of rail segments 21align with one another within each rail assembly 20 along thecorresponding axis 25. Referring briefly to FIG. 7, each rack 32includes a plurality of teeth 36 that are axially adjacent one anotheralong the corresponding rail assembly 20.

Referring still to FIGS. 3 and 4, cable tray 30 comprises an elongatechannel member having a pair of axially extending laterally spaced walls31, 33 that define a channel 29 therebetween. A plurality of footassemblies 35 are coupled to wall 31 via a plurality of threaded collars38. Each foot assembly 35 includes a handle 35 a, a foot 39, and athreaded rod 27 extending therebetween. Threaded rod 27 is threadablyengaged within collar 38 such that rotation of rod 27 via handle 35 aadjusts a position of foot 39 in a generally vertical direction (e.g.,in a direction that is parallel to axis 16—see FIGS. 1-3). A jam nut 37is threadably engaged about threaded rod 27 between handle 35 a andcollar 38. Once a desired position (e.g., vertical position) of foot 39is achieved per rotation of threaded rod 27 within collar 38 aspreviously described, jam nut 27 may be readably advanced along rod 27until it bears against collar 38 (or the structure supporting collar38), thereby placing threaded rod 27 in tension and effectively fixingthe rotational and axial position of threaded rod 27 and foot 29relative to collar 38.

Referring still to FIGS. 3 and 4, wall 33 of cable tray 30 is secured(e.g., bolted, welded, riveted, etc.) to second portion 24 b of secondangle member 24 so that channel 29 extends axially with respect to axis25 in a position that is radially adjacent to second angle member 24. Aswill be described in more detail below, as gantry 50 traverses alongfoundation 4 along axis 12, cable tray 30 (particularly channel 29)align along the corresponding axes 25 to receive cables, hoses, pipes,etc. that are routed to and from gantry 50 and/or printing assembly 150from adjacent devices, sources, equipment, etc., such that the risk ofimpingement of one of the cables, hoses, pipes, etc. with gantry 50during operations is reduced.

Referring again to FIGS. 1-3, gantry 50 generally includes a pair ofvertical support assemblies 60, an upper bridge assembly 70 spanningbetween vertical support assemblies 60, and a trolley bridge assembly110 also spanning between vertical support assemblies 60. As will bedescribed in more detail below, each of the vertical support assemblies60 is movably coupled to a corresponding one of the rail assemblies 20so that vertical support assemblies 60 may traverse along axis 12 duringoperations. In addition, trolley bridge assembly 110 is movably coupledto each of the vertical support assemblies 60 so that trolley bridgeassembly 110 may traverse along axis 16 during operations. Each of thesecomponents will now be described in more detail below.

Referring specifically to FIG. 3, each vertical support assembly 60includes a longitudinal axis 65, a first or lower support frame 62, anda second or upper support frame 64 axially spaced from lower supportframe 62 along axis 65. In addition, vertical support assembly 60includes a plurality of support legs 66 extending axially between frames62, 64 with respect to axis 65. In this embodiment, axis 65 extends inthe vertical direction, or along the direction of the force of gravity,and thus, axis 65 of each vertical support assembly 60 is parallel toaxis 16, and support legs 66 of each vertical support assembly 60 extendvertically between the corresponding girders 62, 64. Further, eachvertical support assembly 60 includes a pair of guide rods 69 extendingaxially between frames 62, 64. As will be described in more detailbelow, guide rods 69 guide trolley bridge assembly 110 as it traversesalong axis 16 relative to vertical support assembles 60 duringoperations.

Referring now to FIGS. 3 and 6, each vertical support assembly 60further includes a plurality of rollers 67 coupled to lower supportframe 62. One or more of the rollers 67 is configured to engage with thealigned angle member 28 within the corresponding rail assembly 20 duringoperations to facilitate the movement of gantry 50 along axis 12. Inparticular, in this embodiment, lower support frame 62 within eachvertical support assembly 60 includes a total of four rollers 67disposed in a pair of rows 68 a, 68 b—namely a first or inner row 68 a,and a second or outer row 68 b. Rows 68 a, 68 b are spaced from oneanother in a radial direction with respect to axis 65 (and thus axiallywith respect to axis 14). In addition, within each vertical supportassembly 60, the inner rows 68 a of roller 67 are more proximate theperimeter 6 of foundation than outer rows 68 b of rollers 67 withrespect to the radial direction of axis 65, when gantry is disposed onrail assemblies 20 in the manner shown in FIGS. 1 and 2.

Referring now to FIG. 6, in this embodiment, rollers 67 of inner rows 68a engage with rails 28 on rail assemblies 20; however, in otherembodiments, the rollers 67 of outer rows 68 b may engage with rails 28.In still other embodiments, the inner row 68 a of rollers 67 of one ofthe vertical support assemblies 60 may engage with a corresponding oneof the rails 28 while the outer row 68 b of the other of the verticalsupport assemblies 60 may engage with the other of the rails 28.Further, in other embodiments, each (or at least one of) the verticalsupport assemblies 60 may include only the inner row 68 a or only theouter row 68 b of rollers 67.

Referring still to FIG. 6, each roller 67 includes a circumferentialchannel 67 a, which in this embodiment is a v-shaped channel or grooveextending circumferentially about roller 67. Channel 67 a engages andmates with elongate angle member 28 of a corresponding one of the railassemblies 20. Thus, during operations, each vertical support assembly60 (and thus also gantry 50—see FIGS. 1 and 2) is configured to traverseaxially with respect to axes 25 of rail assemblies 20 and axis 12 alongand relative to top surface 4 a of foundation 4 via rolling engagementbetween rollers 67 and elongate angle members 28.

A lateral actuation assembly 40 is coupled between each vertical supportassembly 60 and the corresponding rail assembly 20 (that is, there is acorresponding lateral actuation assembly 40 coupled between eachvertical support assembly 60 and corresponding rail assembly 20 withinconstruction system 10). However, it should be appreciated that in otherembodiments, a single lateral actuation assembly 40 is coupled between aselect one of the vertical support assemblies 60 and a corresponding oneof the rail assemblies 20. Each lateral actuation assembly 40 generallycomprises a driver 42 and a connection block assembly 46 for couplingdriver 42 to lower support frame 62 of vertical support assembly 60.

Driver 42 includes an output shaft 41 and is configured to rotate shaft41 about an axis 45 that extends in a direction that is generallyperpendicular to the direction of axis 25 of the corresponding railassembly 20 (however, it should be appreciated that such precisealignment may not exist in other embodiments). Driver 42 may compriseany suitable driver or prime mover for rotating output shaft 41 aboutaxis 45, such as, for example, an electric motor, a hydraulic motor, apneumatic motor, etc. In this embodiment, driver 42 comprises anelectric motor (e.g., a servo motor). In addition, driver 42 isconfigured to rotate shaft 41 in either direction (e.g., clockwise,counterclockwise, etc.) about axis 45. As best shown in FIG. 7, shaft 41is coupled to a gear 43 (e.g., a pinion gear) that includes a pluralityof teeth 44 that are configured to mesh with the teeth 36 of racks 32 ofthe corresponding rail assembly 20.

Referring again to FIG. 6, driver 42 (including shaft 41 and gear 43) ismounted to lower support frame 62 via a connection block assembly 46 aspreviously described. Connection block assembly 46 includes a firstblock or member 52 mounted to driver 42, a second block or member 54mounted to lower frame 62, and a third block or member 56. First block52 includes an aperture 53 that receives shaft 41 of driver 42therethrough along axis 45. A plurality of connector studs 58 (or moresimply “studs 58”) extend through each of the first block 52, secondblock 54, and third block 56. In this embodiment, connector studs 58extend through blocks 52, 54, 56 in a direction that is perpendicular tothe direction of axis 45 of shaft 41. Each stud 58 has a first end 58 a,and a second end 58 b opposite first end 58 a. First block 52 isproximate first ends 58 a of each stud 58, third block 56 is proximatesecond ends 58 b of each stud 58, and second block 54 is disposedbetween blocks 52, 56.

In addition, studs 58 are fixed relative to first block 52 and thirdblock 56 such that studs 58 may not move relative to blocks 52, 56during operations. Any suitable technique may be used to fix studs 58relative to blocks 52, 56, such as for example, engaging nuts to studs58 on either side of blocks 52, 56, threadably engaging studs 58 withinblocks 52, 56, welding studs 58 to blocks 52, 56, etc. In addition, inthis embodiment, studs 58 may freely slide within and relative to secondblock 54. A biasing member (not shown) is disposed between first block52 and second block 54. The biasing member (not shown) is configured tobias first block 52 away from second block 54 along studs 58. In thisembodiment, the biasing member (not shown) may comprise a coiled spring;however, any suitable biasing member configured to linearly bias toblocks 52, 54 apart from one another may be used in other embodiments,such as, for example, a piston. Because studs 58 are fixed relative tofirst block 52 and third block 56, and are free to slide within secondblock 54 as previously described, biasing first block 52 from secondblock 54 along studs 58 also biases third block 56 toward second block54 along studs 58. In addition, the biasing of first block 52 away fromsecond block 54 further along studs 58 biases gear 43 into engagementwith the racks 32 of the corresponding rail assembly 20. Accordingly,connection block assembly 46 is configured to bias teeth 44 of gear 43into cooperative engagement with the corresponding teeth 36 on racks 32during operations (see FIG. 7). It should be appreciated that in otherembodiments, driver 42 is mounted to lower support frame 62 eitherdirectly or via any other suitable frame, bracket, coupling, etc. inplace of connection block assembly 46.

Referring again to FIGS. 1, 6, and 7, during operations, driver 42 ofeach lateral actuation assembly 40 is selectively actuated rotate thecorresponding shaft 41. Due to the engagement between teeth 44 of shafts41 (see FIG. 7) and the teeth 36 of the corresponding racks 32 on railassemblies 20, the rotation of shafts 41 about the corresponding axes 45causes traversal of each vertical support assembly 60 axially along thecorresponding rail assembly 20 with respect to axis 12. Accordingly, theactuation of drivers 42 causes movement or translation of gantry 50along axis 12 relative to foundation 4.

Referring briefly to FIG. 8, in some embodiments, one (or each) of thevertical support assemblies 60 may include an additional wheel or wheels47 mounted to lower support frame 62. As will be described in moredetail below, the additional wheel(s) 47 may be utilized to maneuvergantry 50 either before, during, or after a construction operation. Forinstance, wheel(s) 47 may be used to engage with ramps during loading orunloading of gantry 50 on or from, respectively, a trailer or othersuitable conveyance device. As shown in FIG. 8, in this embodiment,wheel 47 is mounted to lower support frame 62 via a laterally extendingarm 47 a. In addition, in this embodiment, wheel 47 includes a rotatingcaster 47 b that is configured to allow wheel 47 to rotate about agenerally vertically oriented axis 49 (e.g., that may be generallyparallel to and radially offset from axis 16 previously described). Thefree rotation of wheel(s) 47 about the respective axes 49 (that is, inembodiments where multiple wheels 47 are mounted to gantry 50) may allowgantry 50 to be translated as well as rotated along a support surface(e.g., foundation 4, a warehouse floor, a trailer bed, etc.).

Referring again to FIG. 3, upper bridge assembly 70 comprises a pair ofelongate trusses 72 coupled to and spanning between vertical supportassemblies 60. In particular, each truss 72 includes a central axis 75that extends parallel to but is axis 14, a first end 72 a, and a secondend 72 b opposite first end 72 a. In addition, each truss 72 comprises apair of elongate chords or members 74 that extend axially between ends72 a, 72 b and that are radially separated from one another about axis75 and a plurality of webs or stiffening members 76 extending betweenchords 74. Second ends 72 b are secured to one of the vertical supportassemblies 60 via corresponding mounting plates 78 that are furthermounted to corresponding ones of the support legs 66. However, trusses72 are adjustably coupled to the other vertical support assembly 60 suchthat the spacing between vertical support assemblies 60 along trusses 72(or along axes 75, 14) may be adjusted. Accordingly, gantry 50 has awidth W₅₀ extending along axis 14 between vertical support assemblies 60that is adjustable to accommodate different widths of foundation 4 (seeFIGS. 1 and 2).

Referring now to FIGS. 9-14, first ends 72 a of each truss 72 is coupledto one of the vertical support assemblies 60 via a corresponding lateraladjustment assembly 80. Generally speaking, each lateral adjustmentassembly 80 includes a first plate 82, a second pate 84 spaced fromfirst plate 82, and a plurality of rollers 86 coupled to first plate 82.First plate 82 is mounted to a pair of the support legs 66 and secondplate 84 is coupled to first plate 82 such that second plate 84 isspaced from first plate 82 in a radial direction with respect to axes65, 14.

Referring now to FIG. 14, a pair of mounting blocks 95, 97 are mountedto first plate 82 such that mounting blocks 95, 97 are disposed betweenplates 82, 84 during operations. In particular, the mounting blocks 95,97 include a first or upper mounting block 95 and a second or lowermounting block 97 vertically spaced from upper mounting block 95 (e.g.,blocks 95, 97 are spaced in a direction that is parallel to axes 65,16). A first pair of the rollers 86 is rotatably mounted to uppermounting block 95, while a second pair of the rollers 86 is rotatablymounted to lower mounting block 97. A corresponding one of the trusses72 is received between plates 82, 84 such that elongate chords 74 engagewith rollers 86. In particular, the rollers 86 that are rotatablymounted upper mounting block 95 are engaged with a one of the elongatechords 74 of truss 72, and the rollers 86 that are rotatably mounted tolower mounting block 97 are engaged with another of the elongate chords74 of truss 72. During operations, the vertical support assembly 60mounted to lateral adjustment assemblies 80 may translate along trusses72 (e.g., axially with respect to axes 14, 75) relative to the othervertical support assembly 60 via the rolling engagement between rollers86 and elongate chords 74 of trusses 72. Thus, the lateral spacing(e.g., the spacing along axis 14) between vertical support assemblies 60of gantry 50 (and thus the width W₅₀—see e.g., FIGS. 1 and 3) may beadjusted via the rolling engagement between trusses 72 and rollers 86within lateral adjustment assemblies 80, so as to allow gantry 50 tospan across foundations (e.g., foundation 4) having a wide variety ofwidths.

Referring again to FIGS. 9-14, each lateral adjustment assembly 80 alsoincludes a plurality of locking assemblies 88 mounted to first plate 82that are configured to selectively engage with elongate chords 74 so asto fix or lock the position of the corresponding vertical supportassembly 60 along trusses 72 during operations. In particular, eachlocking assembly 88 includes a handle 85, an engagement member 87, and aframe 89 coupled between handle 85 and engagement member 87. As bestshown in FIG. 12, frame 89 includes a first frame member 89 a, a secondframe member 89 b, and a third frame member 89 c. First frame member 89a is mounted to first plate 82, second frame member 89 b is mounted tohandle 85, and third frame member 89 c is mounted to engagement member87. In addition, second frame member 89 b is pinned to each of the firstframe member 89 a and the third frame member 89 c at a first pinnedconnection 81 and a second pinned connection 83, respectively. Duringoperations, the manipulation or movement of handle 85 causes secondframe member 89 b to rotate relative to first frame member 89 a aboutthe first pinned connection 81 so that third frame member 89 c andengagement member 87 are moved toward truss 72 (specifically toward acorresponding one of the elongate chords 74). The movement of thirdframe member 89 c and engagement member 87 is further facilitated by therelative rotation of second frame member 89 b and third frame member 89c about second pinned connection 83. Thus, during operations, when adesired position of trusses 72 and vertical support assemblies 60 (or adesired spacing of vertical support assemblies 60 along axis 14) isachieved, handles 85 of locking assembles 88 may be manipulated to causeengagement members 87 to engage with the trusses 72 of upper bridgeassembly 70 so as to effectively lock the relative positions of verticalsupport assemblies 60 and trusses 72.

In addition, as best shown in FIGS. 9-11, a pair of locking clamps 90 isincluded on lateral adjustment assemblies 80 to selectively adjust thespacing between plates 82, 84. Referring briefly to FIG. 13, eachlocking clamp 90 includes a lever 92, a threaded rod 93 pivotablycoupled to lever 92 and extending through plates 82, 84, and anadjustment nut 94 threadably engaged to threaded rod 93. The threadedrod 93 of one of the locking clamps 90 extends through plates 82, 84 andupper mounting block 95, and the threaded rod 93 of the other lockingclamp 90 extends through plates 82, 84 and lower mounting block 97. FIG.13 only depicts the locking clamp 90 that extends through upper mountingblock 95 to simply the figure; however, it should be appreciated thatthe other locking clamp 90 is configured the same (except that threadedrod 93 extends through lower mounting block 97 as previously described).Threaded rod 93 is pivotably coupled to lever 92 at a pinned connection95. Plates 82, 84 are disposed between lever 92 and adjustment nut 94along rod 93 such that lever 92 is disposed adjacent first plate 82 andadjustment nut 94 is disposed adjacent second plate 84. Lever 92includes a convex curved surface 91 that is engaged with first plate 82,so that during operations, lever 92 may be pivoted about pinnedconnection 95 relative to threaded rod 93 such that convex curvedsurface 91 engages with plate 81 to force plates 82, 84 toward oneanother. In some embodiments, lever 92 may be actuated so as to causeplates 82, 84 to engage and compress truss 72 therebetween to furtherlock or fix the relative positions of vertical support assemblies 60 andvertical bridge assembly 70 during operations. The position of nut 94along rod 93 is configured to selectively adjust the compression appliedto plates 82, 84 and truss 72 when handle 92 is actuated as describedabove.

Referring again to FIGS. 11 and 14, each truss 72 includes an elongaterack 77 that is mounted to one of the elongate chords 74. Rack 77includes a plurality of teeth 79 that are axially adjacent one anotheralong axis 75. A driver 96 is mounted to first plate 82 via a connectionblock assembly 100. Driver 96 includes an output shaft 97 and isconfigured to rotate shaft 97 about an axis 99 that extends in adirection that is generally perpendicular to the direction of axes 65,75. Driver 96 may comprise any suitable driver or prime mover forrotating output shaft 97 about axis 99, such as, for example, anelectric motor, a hydraulic motor, a pneumatic motor, etc. In thisembodiment, driver 96 comprises an electric motor (e.g., a servo motor).In addition, driver 96 is configured to rotate shaft 97 in eitherdirection (e.g., clockwise, counterclockwise, etc.) about axis 99. Asbest shown in FIG. 14, shaft 97 is coupled to a gear 98 (e.g., piniongear) including a plurality of teeth 98 a that are configured to meshwith the teeth 79 of rack 77 of the corresponding truss 72.

Referring still to FIGS. 11 and 14, connection block assembly 100 isgenerally the same as connection block assembly 46 previously describedabove (see e.g., FIG. 6). Thus, connection block assembly 100 includesfirst block or member 52 mounted to driver 69, second block or member 54mounted to first plate 82, and third block or member 56, wherein each ofthe blocks 52, 54, 56 are the same as previously described. In addition,a plurality of connector studs 58 (or more simply “studs 58”) extendsthrough each of the blocks 52, 54, 56 in the same manner as previouslydescribed above. Specifically, studs 58 are fixed within blocks 52, 56and are configured to freely slide or translate within block 54. Withinconnection block assembly 100, studs 58 extend through blocks 52, 54, 56in a direction that is perpendicular to the direction of axes 75, 14.Further, a biasing member 103 is disposed between first block 52 andsecond block 54 so as to bias blocks 52, 54 apart from one another alongstuds 58 and therefore to bias gear 98 into engagement with rack 77mounted to the corresponding truss 72.

Referring now to FIGS. 3, 9, and 14, during operations, the spacing ofvertical support assemblies 60 along axis 14 (and thus also the widthW₅₀) may be selectively adjusted by actuating drivers 96 to rotate gears98 about axes 99. The engagement between teeth 98 a of gears 98 and theteeth 79 on racks 77 causes lateral adjustment assemblies 80 (and thusalso vertical support assemblies 60) to traverse axially along trusses72 with respect to axis 14. Once a desired position or spacing ofvertical support assemblies 60 is achieved, the handles 85 of lockingassemblies 88 are actuated so that engagement members 87 engage withelongate chords 34 of trusses 72, thereby fixing the relative positionsof vertical support assemblies 60 along trusses 72 of upper bridgeassembly 70 as previously described above. The relative position oflateral adjustment assemblies 80 along trusses 72 may also further befixed by manipulating levers 92 of locking clamps 90 to draw plate 82,84 toward one another about the corresponding truss 74 as previouslydescribed above.

Referring again to FIG. 3, trolley bridge assembly 110 includes acentral or longitudinal axis 115 that extends generally parallel to eachof the axes 75 of trusses 72 within upper bridge assembly 70 and axis14. In addition, trolley bridge assembly 110 includes a first end 110 a,a second end 110 b opposite first end 110 a, an elongate base 112, and apair of elongate trusses 114 mounted to base 112, wherein each of thebase 112 and trusses 114 extend axially between ends 110 a, 110 b. Eachtruss 114 includes an elongate axially extending chord 116 and aplurality of webs or stiffening members 118 extending between base 112and chord 116.

Referring briefly to FIG. 19, a plurality of rails 117, 119 are mountedto trolley bridge assembly 110 that extend axially between ends 110 a,110 b. In particular, a pair of first or inner rails 119 extends alongthe base 112 and one of the elongate chords 116 of trusses 114, and apair of second or outer rails 117 extends along the base 112 and theother of the elongate chords 116 of trusses 114. Thus, the inner rails119 are radially spaced from the outer rails 117 about axis 115. Each ofthe rails 117, 119 comprise an elongate angle member that form tracksextending axially along trolley bridge assembly with respect to axis115.

Referring again to FIG. 3, trolley bridge assembly 110 is coupled toeach of the vertical support assemblies 60 such that trolley bridgeassembly 110 may traverse axially along axis 16 during operations. Inparticular, trolley bridge assembly 110 is movably coupled to one of thevertical support assemblies 60 via a first vertical adjustment assembly120 proximate second end 110 b, and is movably coupled to the other ofthe vertical support assemblies 60 via a second vertical adjustmentassembly 140 proximate first end 110 a.

Referring now to FIGS. 3 and 15, first vertical adjustment assembly 120includes a mounting plate 122 that is mounted to trolley bridge assembly110 proximate second end 110 b. A plurality of collars 126 are mountedto plate 122. In particular, in this embodiment, there are a total offour collars 126 disposed in two columns 123 a, 123 b that are axiallyspaced along axis 115 (or spaced in a radial direction with respect toaxis 65 of the corresponding vertical support assembly 60). Each columns123 a, 123 b of collars 126 receives one of the pair of guide rods shownas reference numeral 121 in FIG. 15 (which are the same guide rods thatare shown as reference numeral 69 in FIG. 8, for example) of thecorresponding vertical support assembly 60 axially therethrough withrespect to axes 65, 16. Thus, plate 122 (and trolley bridge assembly110) is free to traverse along axes 65, 16 due to the sliding engagementof guide rods 69 within collars 126.

Referring now to FIG. 16, each vertical support assembly 60 includes achain 124 that extends over a first or upper sprocket 125 that ismounted to upper support frame 64 and a second or lower sprocket 127that is mounter to lower support frame 62. In addition, driver 129 ismounted to lower support frame 62 and is also engaged with chain 124.Driver 129 may comprise any suitable driver, such as those describedabove for drivers 42, 96. In this embodiment, driver 129 comprises anelectric motor (e.g., servo motor). During operations, driver 129 mayengage with chain 124 and rotate in one of two directions (e.g.,clockwise or counter clockwise) to rotate chain 124 in either a firstdirection 104 or a second, opposite direction 108 as shown in FIG. 16.

Referring now to FIGS. 15 and 16, first vertical adjustment assembly 120includes a mounting bracket 128 that is secured to a length of chain 124and to plate 122. Thus, during operations, as driver 129 rotates chain124 in directions 104, 108, plate 122 is moved along with chain 124. Inparticular, when chain 124 is rotated about driver 129, and sprockets125, 127 in direction 104, plate 122 is moved along axially guide rodsshown as reference numeral 121 in FIG. 15 (which are the same guide rodsthat are shown as reference numeral 69 in FIG. 8, for example) towardupper support frame 64 of vertical support member 60 with respect toaxes 65, 16 (or in a vertically upward direction). Conversely, whenchain 124 is rotated about driver 129 and sprockets 125, 127 indirection 108, plate 122 is moved axially along guide rods shown asreference numeral 121 in FIG. 15 (which are the same guide rods that areshown as reference numeral 69 in FIG. 8, for example) toward lowersupport frame 62 of vertical support assembly 60 with respect to axes65, 16 (or in a vertically downward direction).

Referring now to FIGS. 17-19, second vertical adjustment assembly 140includes a mounting plate 142 that further includes a plurality ofcollars 126 arranged in a pair of columns 123 a, 123 b in the samemanner as previously described above for first vertical adjustmentassembly 120. Thus, collars 126 receive guide rods 96 therethrough toallow plate 142 to traverse axially relative to the correspondingvertical support assembly 60 with respect to axis 65. In addition,second vertical adjustment assembly 140 includes a mounting bracket 128that is engaged with the chain 29 disposed on the corresponding verticalsupport assembly 60. Thus, as described with first vertical adjustmentassembly 120, during operations, chain 124 may be actuated to move ortranslate plate 142 axially within vertical support assembly 60 withrespect to axis 65 in the same manner described for first verticaladjustment assembly 120.

As best shown in FIGS. 17 and 19, a plurality of rollers 144 is mountedto plate 142. Each roller 144 includes a circumferential channel 144 a,which in this embodiment is a v-shaped channel or groove extendingcircumferentially about roller 144. Two of the rollers 144 are engagedwith one of the pair of inner rails 119 while the other two of therollers 144 are engaged with the other of the pair of inner rails 119.Thus, during operations, the spacing between vertical support assemblies60 along axes 14, 115 (and thus also the width W₅₀—see e.g., FIGS. 1 and3) may be adjusted via the rolling engagement of rollers 144 and innerrails 119 on trolley bridge assembly 110 (in addition to the rollingengagement of rollers 86 and trusses 72 within upper bridge assembly 70as previously described above).

A plurality of locking assemblies 88, each being the same as previouslydescribed above, are mounted to plate 142 of vertical adjustmentassembly 140. Thus, once a desired spacing between vertical supportassemblies 60 is achieved, handles 85 of locking assemblies 88 on plate142 are manipulated to cause engagement members 87 to engage withtrolley bridge assembly 110 and thereby lock or fix the relativeposition of trolley bridge assembly 110 and vertical support assemblies60 with respect to axis 14 in the same manner previously described forlateral adjustment assemblies 80. Within second vertical adjustmentassembly 140, the engagement members 87 of two of the locking assemblies88 are to engage with the elongate chord 116 of one of the trusses 114of trolley bridge assembly 110 and the engagement members 87 of theother two of the locking assemblies 88 are to engage with the base 112of trolley bridge assembly 110.

Referring specifically now to FIG. 19, an elongate rack 149 is mountedto trolley bridge assembly 110. While not specifically shown, elongaterack 149 includes a plurality of teeth that are similar to teeth 36, 79of racks 32, 77, respectively, previously described above. The teeth(not shown) of rack 149 are axially adjacent one another along axis 115of trolley bridge assembly 110. In addition, a driver 146 is mounted toplate 142 that includes an output shaft 147 and is configured to rotateshaft 147 about an axis 145 that extends in a direction that isgenerally perpendicular to the direction of axis 115 of trolley bridgeassembly 110 (however, it should be appreciated that such precisealignment may not exist in other embodiments). Driver 146 may compriseany suitable driver or prime mover for rotating output shaft 147 aboutaxis 145, such as, for example, an electric motor, a hydraulic motor, apneumatic motor, etc. In this embodiment, driver 146 comprises anelectric motor (e.g., a servo motor). In addition, driver 146 isconfigured to rotate shaft 147 in either direction (e.g., clockwise,counterclockwise, etc.) about axis 145. Further, shaft 147 is coupled toa gear 148 (e.g., a pinion gear) that includes a plurality of teeth (notspecifically shown) mounted thereto that are configured to mesh with theteeth (not shown) of rack 149. Thus, the rotation of gear 148 about axis145 is configured to translate the vertical adjustment assembly 140 (aswell as the vertical support assembly 60 mounted thereto) axially alongtrolley bridge assembly 110 with respect to axis 115.

Referring again to FIG. 18, driver 146 (including shaft 147 and gear148) is mounted to plate 142 via a connection block assembly 143, whichis generally the same as connection block assemblies 46, 100 previouslydescribed. Thus, connection block assembly 143 includes first block ormember 52 mounted to driver 146, second block or member 54 mounted toplate 142, and third block or member 56, wherein each of the blocks 52,54, 56 are the same as previously described. In addition a plurality ofconnector studs 58 (or more simply “studs 58”) extend through each ofthe first block 52, second block 54, and third block 56 in the samemanner as described above, and biasing member 103 is disposed betweenfirst block 52 and second block 54 that is configured to bias firstblock 52 away from second block 54 along studs 58 as previouslydescribed. Thus, biasing member 103 is configured to bias gear 143 intoengagement with rack 149 mounted to trolley bridge assembly 110.

Referring now to FIGS. 1-3 and 20-22, printing assembly 150 generallyincludes a support plate 152 movably mounted to trolley bridge assembly110, and an outflow assembly 151 mounted to plate 152. Support plate 152includes a first or inner side 152 a, and a second or outer side 152 bopposite inner side 152 a. Outflow assembly 151 is mounted to outer side152 b of plate 152. In addition, a plurality of rollers 154 is mountedto inner side 152 a of plate 152. As best shown in FIG. 21, each roller154 includes a circumferential channel 154 a, which in this embodimentis a v-shaped channel or groove extending circumferentially about roller154. During operations, printing assembly 150 is mounted to trolleybridge assembly 110 such that the channel 154 a of each roller 154 isengaged with corresponding ones of the rails 117. In particular, two ofthe rollers 154 are engaged with the rail 117 disposed on the elongatechords 116 of one of the trusses 114 and the other two rollers 154 areengaged with the rail 117 disposed along base 112. Thus, duringoperations, plate 152 of printing assembly 150 may traverse axiallyalong trolley bridge assembly 110 with respect to axes 115, 14 viarolling engagement between rollers 154 and rails 117.

A second elongate rack 167 is mounted to trolley bridge assembly 110. Inparticular, as best shown in FIG. 22, the second elongate rack 167 ismounted on a side of trolley bridge assembly 110 that is radiallyopposite the position of rack 149, previously described. While notspecifically shown, elongate rack 167 includes a plurality of teeth thatare similar to teeth 36, 79 of racks 32, 77, respectively, previouslydescribed above. The teeth (not shown) of rack 167 are axially adjacentone another along axis 115 of trolley bridge assembly 110. In addition,a driver 162 is mounted to outer side 152 b of plate 152 that includesan output shaft 169 extending from outer side 152 b to inner side 152 aof plate 152 and that is configured to rotate shaft 169 about an axis165 that extends in a direction that is generally perpendicular to thedirection of axis 115 of trolley bridge assembly 110 (however, it shouldbe appreciated that such precise alignment may not exist in otherembodiments). Driver 162 may comprise any suitable driver or prime moverfor rotating output shaft 169 about axis 165, such as, for example, anelectric motor, a hydraulic motor, a pneumatic motor, etc. In thisembodiment, driver 162 comprises an electric motor (e.g., a servomotor). In addition, driver 162 is configured to rotate shaft 169 ineither direction (e.g., clockwise, counterclockwise, etc.) about axis165. Further, shaft 169 is coupled to a gear 164 (e.g., a pinion gear)that includes a plurality of teeth (not specifically shown) mountedthereto that are configured to mesh with the teeth (not shown) of rack167. Thus, the rotation of gear 162 about axis 165 is configured totranslate the printing assembly 150 axially along trolley bridgeassembly 110 with respect to axes 115, 14, between vertical supportassemblies 60 during operations.

Referring now to FIGS. 20 and 22, driver 162 (including shaft 169 andgear 164) is mounted to plate 152 via a connection block assembly 163,which is generally the same as connection block assemblies 46, 100, 143previously described. Thus, connection block assembly 163 includes firstblock or member 52 mounted to driver 162, second block or member 54mounted to plate 152, and third block or member 56, wherein each of theblocks 52, 54, 56 are the same as previously described. In addition aplurality of connector studs 58 (or more simply “studs 58”) extendthrough each of the first block 52, second block 54, and third block 56in the same manner as described above, and biasing member 103 isdisposed between first block 52 and second block 54 that is configuredto bias first block 52 away from second block 54 along studs 58 aspreviously described. Thus, biasing member 103 is configured to biasgear 164 into engagement with rack 167 mounted to trolley bridgeassembly 110 during operations.

Referring now to FIGS. 1, 3, 20, and 22, outflow assembly 151 generallyincludes a valve 152 and an outlet nozzle 156 that is downstream ofvalve 152. During operations, extrudable building material is providedto outflow assembly 151 via a supply conduit 155 that is routed trolleybridge assembly 110 on base 112 and between trusses 114 (note: only asmall section of supply conduit 155 is shown in FIG. 3, and the sectionof supply conduit 115 connected to outflow assembly 151 on printingassembly 150 is not shown so as to simply the figure). In particular,the supply conduit 155 is coupled to outflow assembly 151 at a connector153 upstream of valve 152, so that extrudable building material may bedelivered to and through valve 152 and then to outlet nozzle 156 so thatit may be deposited onto foundation 4 (see FIGS. 1 and 2) duringconstruction operations.

Supply conduit 155 is configured to deliver an extrudable buildingmaterial (e.g., a cement mixture) from a source (not shown in FIG. 3),which may comprise any suitable tank, hopper, vessel, etc. that isconfigured to contain a volume of extrudable building material therein.For example, in some embodiments, the source may comprise a tank, acement mixer (e.g., such as that found on a stand-alone cement mixer oron a cement truck), or other suitable container, and may be disposedimmediately adjacent foundation 4 and gantry 50, or may be relativelyremote from foundation 4 and gantry 50. In this embodiment, supplyconduit 155 comprises a hose; however, other suitable conduits orchannels for delivering the extrudable building material from the sourcemay be used in other embodiments (e.g., pipes, open channels, tubing,etc.).

Referring still to FIGS. 1, 3, 20, and 22, valve 152 is an actuatablemember that is configured to selectively close off or adjust the flow ofextrudable building material to outlet nozzle 156 during operations. Insome embodiments, valve 152 comprises a pinch valve; however, othervalve designs or arrangement may be used in other embodiments (e.g.,ball valve, gate valve, butterfly valve, etc.). Valve 152 may beactuated between a fully open position, where valve 152 has little to noeffect on the flow rate of building material flowing to outlet nozzle156, and a fully closed position, where valve 156 prevents allextrudable building material from progressing to outlet nozzle 156 fromsupply conduit 155. In addition, valve 152 may also be actuated to aplurality of positions that are between the fully open and fully closedpositions to progressively adjust the flow of building material tooutlet nozzle 156. Further, in this embodiment, valve 152 ispneumatically actuated with compressed air; however, other actuationmethods are possible, such as, for example, electrical actuation,hydraulic actuation, mechanical actuation, or some combination thereof.

Referring now to FIGS. 1, 3, 20, and 23, during a constructionoperation, printing assembly 150 is traversed along axes 12, 14, 16about foundation 4 via gantry 50 and rail assemblies 20. Simultaneously,printing assembly 150 is actuated (e.g., via a pump assembly 105) toextrude or deposit building material (e.g., a cement mixture) in aplurality of vertically stacked layers 5 a thereby forming structure 5on top surface 4 a of foundation 4. In particular, during theseoperations printing assembly 150 is traversed along the axis 12 viaactuation of drivers 42 and the engagement between teeth 44 on gears 43and teeth 36 on elongate racks 32 mounted on rail assemblies 20 (seeFIGS. 6 and 7). In addition, printing assembly 150 is traversed alongaxis 14 via actuation of driver 162 and the engagement between the teethon gear 164 and the teeth on elongate rack 167 mounted to trolley bridgeassembly 110 (see FIG. 22). Further, printing assembly 150 is traversedalong the axis 16 via actuation of drivers 129 and chains 124 mounted tovertical support assemblies 60 and the corresponding sliding engagementbetween collars 126 on vertical adjustment assemblies 120, 140 and guiderods 69 on vertical support assemblies 60 (see FIGS. 4, 15, and 18).Thus, the selective actuation of drivers 42, 162 causes printingassembly 150 to be controllably maneuvered within a plane that isparallel to top surface 4 a of foundation 4, and the selective actuationof drivers 129 causes printing assembly 150 to be controllablytranslated vertically (or along axis 16).

The above described actuation of drivers 42, 162, 129 may be monitoredand controlled by a central controller 202 (see FIG. 23). Controller 202may comprise any suitable device or assembly which is capable ofreceiving an electrical or informational signal and transmitting variouselectrical, mechanical, or informational signals to other devices (e.g.,valve 201, pump assembly 105, etc.). In particular, in this example,controller 202 includes a processor 204 and a memory 205. The processor204 (e.g., microprocessor, central processing unit, or collection ofsuch processor devices, etc.) executes machine readable instructionsprovided on memory 205 to provide the processor 204 with all of thefunctionality described herein. The memory 205 may comprise volatilestorage (e.g., random access memory), non-volatile storage (e.g., flashstorage, read only memory, etc.), or combinations of both volatile andnon-volatile storage. Data consumed or produced by the machine readableinstructions can also be stored on memory 205. A suitable power sourcemay also be included within or coupled to controller 202 to provideelectrical power to the components within controller 202 (e.g.,processor 204, memory 205, etc.). The power source may comprise anysuitable source of electrical power such as, for example, a battery,capacitor, a converter or a local power grid, etc.

Controller 202 may be coupled to each of the drivers 42, 162, 129 via aplurality of communication paths 203. Communication paths 203 maycomprise any suitable wired (e.g., conductive wires, fiber optic cables,etc.) or wireless connection (e.g., WIFI, BLUETOOTH®, near fieldcommunication, radio frequency communication, infrared communication,etc.). In this embodiment, communications paths 203 comprise conductivewires that are configured to transmit power and/or communication signalsduring operations. In addition, as shown in FIG. 23, controller 202 isalso coupled to a pump 207 via an additional conductive path 203. Pump207 is fluidly coupled between printing assembly 150 and a supply tankor vessel 130 that holds or retains a volume of extrudable buildingmaterial therein. As will be described in more detail below, pump 207 isconfigured to induce a flow of the extrudable building material fromsupply tank 130 to printing assembly 150 via supply conduit 155 whendesired.

During operations, controller 202 selectively actuates drivers 42, 162,129 to controllably maneuver printing assembly 150 along each of theaxes 12, 14, 16, as previously described. In addition, controller 202also actuates pump 207 to controllably flow extrudable building materialfrom supply tank 130 to outlet nozzle 156 of outflow assembly 151.Specifically controller 202 selectively maneuvers printing assembly 150along axes 12, 14, 16 and emits building material from outlet nozzle 156per machine readable instructions (e.g., software) that are stored onmemory 205 and executed by processor 204. Some embodiments of themachine readable instructions are discussed in more detail below;however, it should be appreciated that by executing the machine readableinstructions, layers (e.g., layers 5 a in FIG. 1) of extrudable buildingmaterial are deposited on foundation 4 such that a structure (e.g.,structure 5) is formed or printed from top surface 4 a of foundation 4upward via construction system 10. More particularly, during operations,beads or lines of extrudable building material are deposited by printingassembly 150 so as to form a vertical layer 5 a of structure 5, and thenthe printing assembly 150 is raised and once again maneuvered over thepreviously printed layer 5 a to thereby deposit another vertical layer 5a of structure 5 a atop the first printed layer 5 a. Referring brieflyto FIG. 3, in this embodiment, controller 202 may be disposed within astorage cabinet 209 that is mounted or secured to one of the verticalsupport assemblies 60 of gantry 50. However, it should be appreciatedthat the location of controller 202 may be varied in other embodiments.

Referring still to FIGS. 3, 20, and 23, controller 202 is also coupledto valve 152 via a communication path 203 and is configured to actuatevalve 152 between the fully open position, the fully closed position,and to the plurality of positions that are between the fully open andfully closed positions to progressively adjust the flow of buildingmaterial emitted from outlet nozzle 156. During operations, controller202 may actuate valve 152 (e.g., via a compressed air or other actuationsystem) to a desired position. In some embodiments, controller 202 isconfigured to actuate valve 152 based on a number of factors, such as,for example, the operating status of pump 207, the portion of thestructure (e.g., structure 5 shown in FIG. 1) that is to be constructed(e.g., printed), the length of supply conduit 155 between pump 207 andvalve 152 (and/or outflow conduit 110), etc.

Without being limited to this or any other theory, the actuation ofvalve 152 may allow for precise control of the outflow of extrudablebuilding material from outlet nozzle 156 during operations. For example,referring now to FIGS. 1-3, 23, and 24, a method 210 for printing ordepositing a layer of extrudable building material (e.g., a cementmixture) is shown. Method 210 may be practiced wholly or partially bycontroller 202 (e.g., by processor 204 executing machine readableinstructions stored on memory 205) within construction system 10. As aresult, continuing reference is made to construction system 10 indescribing the features of method 210 of FIG. 24 and continuingreference is made to FIGS. 1-3 and 23 in addition to FIG. 24. However,it should be appreciated that other assemblies, systems, and/orpersonnel may be used to carry out method 210 in other embodiments.Thus, in describing method 210, references to the actions or functionsof controller 202 or the features of construction system 10 are meant toexplain or describe particular embodiments of method 210 and should notbe interpreted as limiting all possible embodiments of method 210.

Initially, method begins by actuating valve 152 within outlet assembly151 to the fully closed position at 215. As a result, extrudableprinting material is prevented from flowing out of outlet nozzle 156.Next, method 210 includes actuating pump 207 at 220 to initiate the flowof extrudable building material from supply tank 130 toward printingassembly 150 at 220. However, even after the valve 152 is actuated at220, the flow of extrudable building material is prevented from exitingoutlet nozzle 156 by the closed valve 152. Next, at 225, method enquiresas to whether a time X has elapsed after actuating pump 207 to beginpumping extrudable building material from supply tank 130. The time Xmay be set or configured to allow the extrudable building material tofill the supply conduit 155 between pump 207 and outflow assembly 151such that the flow of extrudable building material from outlet nozzle156 may begin relatively quickly (e.g., nearly immediately) afteropening valve 152. Thus, the value or range of time X may vary dependingon a variety of factors, such as, for example, the length of supplyconduit 155, the flow rate from pump 207, the viscosity of theextrudable building material, etc. If, at 225, it is determined that thetime X has not elapsed since actuating the pump 207 in 220 (i.e., thedetermination at 225 is “No”), then method 210 repeats block 225 to onceagain enquire as to whether time X has elapsed. If, on the other hand,it is determined at 225 that time X has elapsed (i.e., the determinationat 225 is “Yes”), then method 210 proceeds to actuate valve 152 to anopen position (e.g., the fully open position or a partially openposition) and to actuate the printing assembly 150 to traverse along thefoundation 4 to deposit a layer 5 a of structure 5 at 230. Inparticular, as previously described above, within block 230, controller202 may actuate drivers 42, 162 to maneuver printing assembly 150 withina plane that is parallel to top surface 4 a of foundation 4 whileextrudable building material is emitted from outlet nozzle 156 via theopen valve 152 so that a layer 5 a of structure 5 is deposited thereon.During these operations, it may be desirable to deposit an entire layer5 a of structure 5 in series of continuous lateral movements of printingassembly 150 (e.g., via gantry 50) while the valve 152 remains in theopen position within 230. However, it should be appreciated that thelateral movements of printing assembly 150 at 230 may comprise aplurality of non-continuous movements (whereby the valve 152 is actuatedbetween the open and closed position to start and stop the flow ofextrudable building material therethrough during the non-continuousmovements).

Referring still to FIGS. 1-3, 23, and 24, at 235, method 210 enquires asto whether the remaining length of extrudable building material to printwithin a given layer 5 a is greater than zero and less than Y at 235.The length Y may be set or configured to correspond to the expectedprinting length that may be carried out after the pump 207 is turned offsuch that additional extrudable building material is no longer beingprovided into supply conduit 155 from supply tank 130. Thus, the lengthY may vary depending on a variety of factors, such as, for example, thelength of supply conduit 155, the flow rate from pump 207, the speed ofmovement of printing assembly 150 across foundation, the thickness ofthe printed beads or lines of extrudable building material, etc. If itis determined at 235 that the remaining length to print within a givenlayer 5 a is greater than length Y (i.e., the enquiring at block 235 is“No”) then method 210 repeats the enquiry at block 235. If, on the otherhand, it is determined at 235 that the remaining length to print withina given layer 5 a is greater than zero and less than Y, then method 210proceeds to turn off the pump 207 at 240.

Next method 210 enquires as to the remaining length to print within agiven layer is greater than zero and less than Z at 245. The length Zmay be set or configured to correspond to the expected printing lengththat may be carried out once the valve 152 is closed. In particular, asmay be appreciated in FIG. 20, because the valve 152 is disposedupstream of outlet nozzle 156, some extrudable building material (e.g.,the amount of material that may be disposed between the valve 152 andthe outlet of nozzle 156) may be emitted from nozzle 156 after valve 152is actuated to the fully closed position. Thus, like the length Y atblock 235, the length Z may vary depending on a variety of factors, suchas, for example, the length and volume between valve 152 and outletnozzle 156, the speed of movement of printing assembly 150 acrossfoundation, the thickness of the printed beads or lines of extrudablebuilding material, etc. In various embodiments, the length Z is lessthan the length Y. If it is determined at 245 that the remaining lengthto print within a given layer 5 a is greater than Z (i.e., the enquiringat block 245 is “No”) then method 210 repeats the enquiry at block 245.If, on the other hand, it is determined at 245 that the remaining lengthto print within a given layer 5 a is less than Z, then method 210proceeds to actuate the valve 152 to the fully closed position at 250.

Next, method 210 enquires as to whether the output nozzle 156 hasreached the end point of the layer 5 a being printed at 255. If, forexample, it is determined that the output nozzle 156 has not reached theend point of the given layer 5 a (i.e., the determination at 255 is“No”), then method 210 repeats the enquiry at 255. If, on the otherhand, it is determined that the output nozzle 156 has reached the endpoint of the given layer 5 a at 255 (i.e., the determination at 255 is“Yes”), then method 210 includes reversing the output nozzle a length θover the previously printed line at 260. For instance, once the printingassembly 150 has reached an end point of a (or the) line forming a givenlayer 5 a of structure 5, controller 202 may then maneuver the printingassembly 150 such that outlet nozzle 156 reverses direction and retracessome length (e.g., length θ) over the previously printed line. Withoutbeing limited to this or any other theory, the movement at 260 may allowextrudable building material to be wiped or removed from outlet nozzle156 by engagement with the previously printed bead or line. Thus, when asubsequent layer 5 a or line is to be printed by printing assemblyfollowing method 210, the nozzle 156 may be substantially clear ofpreviously extruded building material.

When performing a printing operation of a structure, construction system10 (including gantry 50) may be delivered on a truck-pulled trailer tothe build site (which may already have a foundation in place). Forinstance, referring now to FIGS. 25-27, a series of sequential views ofan example construction process utilizing construction system 10 areshown. Generally speaking, FIGS. 25 and 26 show the delivery and initialset-up of construction system 10 on an existing foundation 310, and FIG.27 depicts construction system 10 during a printing operation ofmultiple structures 350 on foundation 310. In the process depicted inFIGS. 25-27, a plurality of structures 350 are constructed (e.g.,printed) by construction system 10 on a single, elongated foundation310. Such a construction process may be useful or desirable forconstructing structures (e.g., dwellings) for a population that liveswithin a fairly remote or economically disadvantaged area. For instance,such a construction process may be useful or desirable for constructingmultiple family homes within a rural village.

Referring specifically first to FIG. 25, initially the gantry 50 ofconstruction system 10 is delivered to a construction site via atruck-pulled trailer 302. In this embodiment, trailer 302 is a so-called“drop-deck” flatbed trailer that includes a longitudinal axis 305, afirst or front end 302 a, a second or rear end 302 b opposite front end302 a, a first or front raised deck 304 extending axially from front end302 a, a second or rear raised deck 308 extending axially from rear end302 b, and a central drop deck 306 extending axially between raiseddecks 304, 308. As shown in FIG. 25, gantry 50 is disposed on drop decksuch that axes 75 of trusses 72 within upper bridge assembly 70 and axis115 of trolley bridge assembly 110 are generally oriented parallel toaxis 305 of trailer 302.

In this embodiment, foundation 310 is already formed (e.g., poured) whengantry 50 is delivered via trailer 302; however, in other embodimentsgantry 50 may be delivered before or during the formation (e.g.,pouring) of foundation 310. In addition, in this embodiment, foundation310 is an elongated rectangle so as to allow the construction ofmultiple structures (e.g., structures 350) thereon as previouslydescribed above. Thus, foundation 310 includes a pair of opposing minoror short sides 311 and a pair of opposing major or long sides 312 (note:only one of the short sides 311 is visible in FIG. 25). In thisembodiment, trailer 302 is maneuvered such that axis 305 generallyextends along one of the short sides 311 of foundation 310.

Referring now to FIG. 26, after pulling trailer 302 along one of theshort sides 311 of foundation 310, gantry 50 is offloaded from trailer302 directly onto foundation 310 with one or more ramps 303. Inparticular, gantry 50 is loaded off of trailer 302 and onto foundation310 in a generally radial direction with respect to axis 305 of trailer302. Thus, gantry 50 is offloaded from a side of trailer 302. Duringthis process, rollers 67 mounted to lower support frames 62 of verticalsupport assemblies 60 may engage with ramps 303 or additional wheels maybe mounted to lower support frames 62 (e.g., such as wheels 47 shown inFIG. 8) that are to engage with ramps 303 during this process.Regardless of the method of engaging with ramps 303, in someembodiments, the spacing of vertical support assemblies 60 may beadjusted along upper bridge assembly 70 and trolley bridge assembly 110in the manner described above such that rollers 67, additional wheels,or other engagement mechanisms coupled to gantry 50 may be aligned withramps 303 during offloading of gantry 50 onto foundation 310. Forexample, the spacing between vertical support assemblies 60 of gantry 50(and thus also the width W₅₀) may be adjusted via rolling engagement ofrollers 86 with trusses 72 and rolling engagement of rollers 144 andtrolley bridge assembly 110 as previously described (see e.g., FIGS. 3,10, and 17). In addition, in some embodiments gantry 50 may be pulledalong ramps 303 from trailer 302 to foundation by a winch or othersuitable device (not shown).

In addition, before, during, or after initially offloading gantry 50from trailer 302 onto foundation 310, rail assemblies 20 (previouslydescribed above) may be mounted to and along the long sides 312 offoundation 310. In particular, referring briefly again to FIG. 6 inaddition to FIG. 26, rail assemblies 20 may be mounted to long sides 312by engaging a plurality of bolts 21 through slots 23 in first elongateangle member 22 into foundation 310. Thus, in some embodiments, whengantry 50 is offloaded onto foundation 310, gantry 50 is guided downramps 303 such that rollers 67 engage with rails 28 formed along railassemblies 20 (see FIG. 6). Due to the placement of ramps 303, in theseembodiments, the additional wheel(s) that may be mounted to lowersupport frame 62 (e.g., wheel 47 previously described and shown in FIG.8) may engage with ramps 303 so as to guide rollers 67 on lower frames64 into engagement with rails 28 on rail assemblies 20.

Referring now to FIGS. 26 and 27, once gantry 50 is disposed onto rails28 of rail assemblies 20 as previously described, gantry 50 may beutilized to print one or more structures 350 (e.g., dwellings) onfoundation 310. In particular, in this embodiment, the structures 350are arranged side by side on foundation 310 along long sides 312.Because each of the structures 350 are arranged on a single foundation,gantry 50 may print structures 350 in sequential order while generallyprogressing along long sides 312 of foundation 310. During theseprinting operations, extrudable building material (e.g., a cementmixture) may be mixed and delivered to gantry 50 on foundation 310. Forinstance, in some embodiments, dry ingredients 362 of the extrudablebuilding material may be delivered on a separate truck or other suitableconveyance device 360. These dry components may be mixed (e.g.,continuously or in batches) in a separate mixing unit (e.g., a mixingtruck and/or standalone mixing unit) and then delivered (e.g., pumped)to gantry 50 (specifically printing assembly 150 previously describedabove). Thus, in at least some embodiments, one or both of the longsides 312 of foundation 310 may be generally aligned with a suitableroad way or path to allow delivery of the extrudable building materialsto gantry 50 during printing operations of the adjacent structures 350.

During construction operations with construction system 10 (e.g., suchas the construction process shown in FIGS. 25-27), extrudable buildingmaterial (e.g., a cement mixture) is mixed and provided to printingassembly 150 movably disposed on gantry 50 as previously described (seee.g., FIGS. 1 and 23). In some embodiments, the extrudable buildingmaterial is delivered pre-mixed to the construction site and provided(e.g., pumped) to printing assembly 150. However, in other embodiments,the extrudable building material is mixed at the construction site andprovided to printing assembly 150 either continuously or in batches tofacilitate the construction of one or more structures (e.g., structures350 shown in FIG. 27). For example, referring now to FIGS. 28 and 29,construction system 10 (see e.g., FIGS. 1-3, 23) may include a materialdelivery system 400 for mixing and delivering extrudable buildingmaterial to printing assembly 150 during operations. In this embodiment,material delivery system 400 is configured to mix and deliver anextrudable building material that comprises a cement mixture; however,it should be appreciated that other embodiments of material deliverysystem 400 may be configured to mix and/or deliver other types ofextrudable building materials (e.g., other than cement mixtures).

In this embodiment, material delivery system 400 is disposed upon atrailer 402 that includes a longitudinal axis 405, a first or front end402 a, a second or rear end 402 b opposite front end 402 a, and a deck408 extending axially between ends 402 a, 402 b. In addition, trailer402 includes a hitch 404 at front end 402 a and a plurality of wheels406 disposed under deck 408. During operations, trailer 402 may beattached to a vehicle (either directly or indirectly through a secondtrailer) and towed to a construction site (e.g., such the constructionsite shown in FIGS. 25-27).

Referring still to FIGS. 28 and 29, material delivery system 400includes a number of components disposed on deck 408 of trailer 402 formixing and delivering the extrudable building material to printingassembly 150 (see FIG. 3) during operations. Specifically, in thisembodiment, material delivery system includes one or more water tanks410, a dry ingredient hopper 412, and a mixing unit 414 including anoutlet 416 for emitting the mixed building material. In addition,material delivery system 400 also includes a storage cabinet 420 forenclosing various components (e.g., such as electronic components asdescribed in more detail below). While not specifically shown in FIGS.28 and 29, each of the tanks 410, hopper 412, and mixing unit 414 are incommunication with one another (in a manner to be described in moredetail below) so as to mix batches the extrudable building material,which are then provided to printing assembly 150 of construction system10 (see FIGS. 1 and 23) via outlet 416.

Referring now to FIG. 30, a schematic diagram of material deliverysystem 400 is shown. Tank(s) 410 are coupled to mixing unit 414 via afirst line 411. A pump 422 is disposed along first line 411 and isconfigured to be driven by a motor or driver 423 to pressurize anddeliver fluid (e.g., water) from tank(s) 410 to mixing unit 414 duringoperations. Pump 422 may be any suitable design or type, such as, forexample a centrifugal pump, a positive displacement pump, a screw pump,etc. In addition, driver 423 may be any suitable driver or motorconfigured to drive pump 422 during operations, such as, for example, anelectric motor, a hydraulic motor, an internal combustion style motor,etc. In this embodiment, driver 423 is an electric motor.

Hopper 412 comprises an upper funnel 417 is configured to receivebatches of dry ingredients of extrudable building material duringoperations. In particular, referring briefly again to FIGS. 28 and 29,funnel 417 may normally be closed within an upper lid 418. However, whenit is desired to provide additional dry ingredients (e.g., which maycomprise the dry ingredients and/or powders, gravel of a cement mixture)lid 418 is removed and a volume of these dry ingredients are insertedwithin funnel 417. For instance, in some embodiments, a crane, forklift,or other suitable device may be used to lift a bag (e.g., a bailer bag)of these dry ingredients over funnel 417 such that they may then bedeposited therein.

Referring again to FIG. 30, hopper 412 also includes a mixing device432, which in this embodiment comprises an auger, disposed below funnel417 that is rotated by a driver 430 to mix and deliver the dryingredients from hopper 412 to mixing unit 414 via a line 413. Asdescribed above for driver 422, driver 430 may comprise any suitabledriver or motor (e.g., such as those listed above for driver 422). Inthis embodiment, driver 430 comprises an electric motor. Lines 411, 413extending between tank(s) 410, hopper 412, and mixing unit 414 maycomprise any suitable conduit or other conveyance member for deliveringor channeling liquid or solid materials between two points or locations.For instance, in some embodiments, line 411 may comprise a hose, pipe,channel, and line 413 may comprise a belt, tube, duct, etc.

Mixing unit 414 includes a tank or volume 415 that receives water fromtank(s) 410 via line 411 and dry ingredients from hopper 412 via line413. In addition, mixing unit includes an agitator 435 disposed withinvolume 415 that is configured to mix the liquid and dry ingredientsprovided from tank(s) 410 and hopper 412 during operations. In thisembodiment, agitator 435 comprises shaft 436 and a plurality of paddles438 or other suitable mixing devices mounted to and extending outwardfrom shaft 436. Shaft 436 is operatively coupled to a driver 434 that isconfigured to rotate shaft 436 and paddles 438 within volume 415 duringoperations to thereby mix the liquids and dry ingredients provided fromlines 411 and 413, respectively, during operations. As with drivers 422,430, driver 434 may comprise any suitable driver or motor (e.g., such asthose listed above for driver 422). In this embodiment, driver 434comprises an electric motor. A valve 419 is disposed along outlet 416from mixing unit 414. As will be described in more detail below, valve419 is actuated to selectively deliver mixed, extrudable buildingmaterial from volume 415 to supply tank 130 (see FIG. 23) for subsequentuse within printing assembly 150 as previously described above.

Referring still to FIG. 30, material delivery system 400 also includes acontroller 450 that is generally configured to control drivers 423, 430,434 and valve 419 of material delivery system 400. In this embodimentcontroller 450 is disposed within cabinet 420; however, in otherembodiments, controller 450 may be disposed in any suitable location,including locations that are not located on trailer 402 (see FIGS. 28and 29). Controller 450 may be a standalone controller that is tocontrol various components of material deliver system 400 as mentionedabove, or may be integrated within a broader controller unit orcontroller for construction system 10 (e.g., such as controller 202previously described above). In this embodiment, controller 400 is adedicated control unit for material delivery system 400, and maycomprise any suitable device or assembly which is capable of receivingan electrical or informational signal and transmitting variouselectrical, mechanical, or informational signals to other devices (e.g.,drivers 423, 430, 434, valve 419, etc.). In particular, in this example,controller 450 includes a processor 452 and a memory 454. The processor452 (e.g., microprocessor, central processing unit, or collection ofsuch processor devices, etc.) executes machine readable instructionsprovided on memory 454 to provide the processor 452 with all of thefunctionality described herein. The memory 454 may comprise volatilestorage (e.g., random access memory), non-volatile storage (e.g., flashstorage, read only memory, etc.), or combinations of both volatile andnon-volatile storage. Data consumed or produced by the machine readableinstructions can also be stored on memory 454. A suitable power sourcemay also be included within or coupled to controller 450 to provideelectrical power to the components within controller 450 (e.g.,processor 452, memory 454, etc.). The power source may comprise anysuitable source of electrical power such as, for example, a battery,capacitor, a converter or a local power grid, etc.

Controller 450 may be coupled to each of the drivers 423, 430, 434 andvalve 419 via a plurality of communication paths 451. Communicationpaths 451 may comprise any suitable wired (e.g., conductive wires, fiberoptic cables, etc.) or wireless connection (e.g., WIFI, BLUETOOTH®, nearfield communication, radio frequency communication, infraredcommunication, etc.). In this embodiment, communications paths 451comprise conductive wires that are configured to transmit power and/orcommunication signals during operations.

During operations controller 450 is configured to selectively actuatedrivers 423, 430, 434 so as to selectively actuate pump 422, auger 432,shaft 436, respectively. In addition, controller 450 is configured toselectively actuate valve 419 between a fully closed position (wherebyno building materials are allowed to flow through outlet 416), a fullyopen position (whereby building materials are allowed to freely flowthrough outlet 416), and a plurality of positions between the fullyclosed position and the fully open position. Valve 419 may be actuatedby any suitable method or device (e.g., electrically, hydraulically,magnetically, etc.). In this example, controller 450 is configured toelectrically actuate valve 419 as described above via the correspondingcommunication path 451.

Further, controller 450 is configured to measure or detect a torqueimparted to shaft 436 due to the resistance or viscosity of the buildingmaterials within volume 415 of mixing unit 414. For instance, controller450 may measure or detect the torque imparted to shaft 436 with asuitable sensor or measurement device within driver 434 or mounted toshaft 436 itself. In other examples, controller 450 may determine thetorque imparted to shaft 436 by analyzing the electrical load drawn bydriver 434 when rotating shaft 436 during operations.

Generally speaking during mixing operations, controller 450 actuatespump 422 and auger 432 via drivers 423 and 430, respectively, to deliverwater from tank 410 and dry ingredients from hopper 412 into volume 415of mixing unit 414. In addition, controller 450 actuates driver 434 torotate shaft 436 and paddles 438 within volume 415 to mix the water anddry ingredients together. During this process, controller 450 maymeasure the torque load imparted to shaft 436 by the materials disposedwithin volume 415. If the torque load is above a first threshold, thencontroller 450 may determine (e.g., via execution of machine readableinstructions with processor 452) that the viscosity of the mixture involume 115 is too high and that additional water should be added. As aresult, controller 450 may actuate pump 422 to provide additional waterfrom tank(s) 410 to volume 415 via line 411. If, on the other hand, ifthe torque load imparted to shaft 436 is below a second threshold (thatis lower than the first threshold) then controller 450 may determinethat the viscosity of the mixture in volume 115 is too low and thatadditional dry ingredients should be added. As a result, controller 450may actuate auger 432 to provide additional dry ingredients to volume415 via line 413. If the torque load imparted to shaft 436 is between orequal to the first threshold and the second threshold, controller 450may determine that the batch mixture within volume 415 of mixing unit414 has the appropriate proportions of water and dry ingredients andthen may actuate valve 419 to the open position (when desired) todeliver the mixed, extrudable building material to printing assembly 150(or supply tank 130 that is to supply the building material to printingassembly 150 as previously described—see e.g., FIG. 23). Thus,controller 450 and mixing unit 414 may form a rheometer for ensuringthat the extrudable building material delivered to printing assembly 150includes a consistent mixture, and thereby exhibits a consistentperformance during a construction operation.

Referring now to FIG. 31, a method 500 for mixing and delivering anextrudable building material to a printing assembly (e.g., printingassembly 150) with material delivery system 400 is shown. Method 500 maybe practiced wholly or partially by controller 450 (e.g., by processor452 executing machine readable instructions stored on memory 454) withinmaterial deliver system 400. As a result, continuing reference is madeto material delivery system 400 in describing the features of method500. However, it should be appreciated that other assemblies, systems,and/or personnel may be used to carry out method 500 in otherembodiments. Thus, in describing method 500, references to the actionsor functions of controller 450 or the features of material deliverysystem 400 are meant to explain or describe particular embodiments ofmethod 500 and should not be interpreted as limiting all possibleembodiments of method 500.

Initially, method 500 begins by actuating pump 422 to provide water tomixing unit 414 at 505 and actuating auger 432 to provide dryingredients to the mixing unit at 510. Next, method 500 includesactuating the mixing unit motor 434 to rotate mixing paddles 438 at 515.In particular, at 515, the paddles 438 are rotated within the volume 415of mixing unit 414 to mix and combine the water and dry ingredientsprovided to mixing unit 414 at 505 and 510, respectively. Next, method500 includes measuring the torque imparted to the mixing unit motor 434at 520 during the rotating of the paddles 438 at 515. In particular, aspreviously described above, the torque imparted to the mixing unit motor434 may be measured by, for example, analyzing the electrical currentdrawn by the mixing unit motor 434 during the rotation of the paddles438 and/or by receiving an output signal from one or more sensors orother measurement devices coupled to paddles 438, motor 434, or othersuitable components.

Referring still to FIG. 31, once the torque imparted on the mixing unitmotor 434 is measured at 520, method 500 enquires as to whether themeasured torque is above a first threshold at 525. If the measuredtorque from 520 is above the first threshold in 525 (i.e., thedetermination at 525 is “Yes”), then method 500 proceeds to 545 wherebyadditional water is provided to mixing unit 414 (e.g., via pump 422 aspreviously described). The amount of the additional water provided tothe mixing unit 414 may be a predetermined, incremental amount orvolume, or it may be determined (e.g., by controller 450) based on themeasured torque at 520 (e.g., such as a difference between the measuredtorque and the first threshold in 525). After the additional water issupplied to the mixing unit 434 at 535, method 500 returns to 520 toonce again measure the torque imparted to the mixing unit motor 434.

If, on the other hand, the determination at 525 is that the measuredtorque at 520 is not above the first threshold value (i.e., thedetermination at 525 is “No”), then method 500 proceeds to enquire as towhether the measured torque from 520 is below a second threshold at 530.The second threshold 530 may be below the first threshold in 525. If themeasured torque from 520 is below the second threshold in 530 (i.e., thedetermination at 530 is “Yes”), then method 500 proceeds to 540 wherebyadditional dry ingredients are provided to mixing unit 414 (e.g., viaauger 432 as previously described). The amount of the additional dryingredients provided to the mixing unit 414 at 540 may be apredetermined, incremental amount or volume, or it may be determined(e.g., by controller 450) based on the measured torque at 520 (e.g.,such as a difference between the measured torque and the secondthreshold in 530). After the additional dry ingredients are supplied tothe mixing unit 434 at 540, method 500 returns to 520 to once againmeasure the torque imparted to the mixing unit motor 434.

If, on the other hand, the determination at 530 is that the measuredtorque at 520 is not below the second threshold value (i.e., thedetermination at 530 is “No”), then method 500 proceeds to enquire as towhether the printing assembly building material source tank is below aminimum level at 545. In particular, in some embodiments the printingassembly source tank comprises the supply tank 130 shown in FIG. 23.Thus, in these embodiments, supply tank 130 may include a level sensor(not shown) that communicates either directly with controller 450 orthrough another control unit (e.g., controller 202 shown in FIG. 23), sothat controller 450 is able to determine, at 545, whether the levelwithin supply tank 130 is below some minimum depth so that additionalbuilding material should be delivered thereto to support constructionoperations with printing assembly 150. Therefore, if the determinationat 545 is that the level of the printing assembly supply tank 130 isbelow the minimum level (i.e., the determination at 545 is “Yes”), thenmethod proceeds to 550 to actuate valve 419 to an open position (e.g.,the fully open position or a partially open position) to provide themixed, extrudable building material to supply tank 130. If, on the otherhand, it is determined that the level within supply tank 130 is notbelow the minimum level at 545 (i.e., the determination at 545 is “No”),then method 500 returns to 520 to once again measure the torque impartedto the mixing unit motor 434. Thus, the enquiries 525 and 530 arerepeatedly performed until the extrudable building material is deliveredto the source at 550 so as to ensure that the extrudable buildingmaterial includes the desired proportions of ingredients (namely waterand dry ingredients).

The first and second threshold values discussed above within blocks 525and 530, respectively, of method 500 may be determined based on adesired proportion of water to dry ingredients within the extrudablebuilding material. For example, in some embodiments, the extrudablebuilding material may comprise a cement mixture including cement, graveland other dry ingredients that are mixed with a desired amount of waterprior to extrusion by the printing assembly 150. Thus, the first andsecond threshold values may be set to result in a desired viscositywhich is in turn associated with a desired proportion of water to dryingredients within the cement mixture. In some embodiments, the firstand second threshold values may be equal or substantially equal to oneanother, and in other embodiments, the first and second threshold valuesmay be different (e.g., with the second threshold value being smaller orlower than the first threshold value as previously described).

In the manner described, systems and methods for designing andconstructing a structure via 3D printing have been described. In someembodiments, the above described methods and systems may be utilizedwith any one of the constructions systems previously described herein toconstruct a structure. Accordingly, by use of the systems and methodsdisclosed herein, the time and materials required to construct astructure may be reduced.

While exemplary embodiments have been shown and described, modificationsthereof can be made by one skilled in the art without departing from thescope or teachings herein. The embodiments described herein areexemplary only and are not limiting. Many variations and modificationsof the systems, apparatus, and processes described herein are possibleand are within the scope of the disclosure. Accordingly, the scope ofprotection is not limited to the embodiments described herein, but isonly limited by the claims that follow, the scope of which shall includeall equivalents of the subject matter of the claims. Unless expresslystated otherwise, the steps in a method claim may be performed in anyorder. The recitation of identifiers such as (a), (b), (c) or (1), (2),(3) before steps in a method claim are not intended to and do notspecify a particular order to the steps, but rather are used to simplifysubsequent reference to such steps.

What is claimed is:
 1. A method of constructing a structure, the methodcomprising: (a) adjusting a width of a gantry, wherein the gantrycomprises: a first vertical support assembly; a second vertical supportassembly; a trolley bridge assembly coupled to and extending between thefirst and second vertical support assemblies; and a printing assemblymovably coupled to the trolley bridge assembly; wherein the width of thegantry extends between the first and second vertical support assembliesand is adjusted by rolling engagement between the first vertical supportassembly and a truss; (b) engaging the first and second vertical supportassemblies with a pair of rail assemblies mounted to opposing sides of afoundation; (c) translating the first and second vertical supportassemblies along a first axis relative to the pair of rail assemblies;(d) translating the printing assembly along a second axis that isorthogonal to the first axis relative to the trolley bridge assembly;and (e) extruding an extrudable building material from the printingassembly during (c) and (d).
 2. The method of claim 1, wherein the trussextends between the first and second vertical support assemblies alongthe second axis; and wherein (a) comprises sliding the truss along aplurality of rollers coupled to the first vertical support assembly. 3.The method of claim 1, wherein (a) comprises sliding the trolley bridgeassembly along a plurality of rollers coupled to the first verticalsupport assembly.
 4. The method of claim 1, further comprising: (f)translating the trolley bridge assembly and the printing assembly alonga third axis relative to the first vertical support assembly and thesecond vertical support assembly, wherein the third axis is orthogonalto both the first axis and the second axis.
 5. The method of claim 4,wherein (f) further comprises: (f1) rotating a chain coupled to thefirst vertical support assembly; and (f2) sliding a collar coupled tothe trolley bridge assembly along a guide rod mounted to the firstvertical support assembly.
 6. The method of claim 1, wherein (c)comprises actuating a first driver with a controller; wherein (d)comprises actuating a second driver with the controller.
 7. The methodof claim 1, wherein the printing assembly comprises a valve; and whereinthe method further comprises: (g) actuating the valve to a closedposition; (h) preventing the extrudable building material from beingextruded from the printing assembly as a result of (g); (h) actuating apump to induce a flow of the extrudable building material from a tank tothe printing assembly; (i) waiting a first predetermined period of timeX after (h); (j) actuating the valve to an open position after waitingthe predetermined period of time X; and (k) extruding the extrudablebuilding material from the printing assembly as a result of (j).
 8. Themethod of claim 7, further comprising: (l) depositing the extrudablebuilding material to form a layer of the structure on the foundation;and (m) turning off the pump to prevent the flow of the extrudablebuilding material from the tank to the printing assembly when aremaining length of the extrudable building material to be depositedwithin the layer is greater than zero and less than Y.
 9. The method ofclaim 8, further comprising: (n) actuating the valve to the closedposition to prevent flow of the extrudable building material from theprinting assembly when the remaining length of the extrudable buildingmaterial to be deposited within the layer is greater than zero and lessthan Z, wherein Z is less than Y; and (o) reversing the printingassembly a non-zero distance θ over the previously deposited extrudablebuilding material within the layer after depositing all of theextrudable building material within the layer.
 10. The method of claim1, further comprising: (p) delivering the gantry to the foundation on atrailer, wherein the trailer has a longitudinal axis; and (q) moving thegantry down a pair of ramps from the trailer to the foundation, whereinthe ramps extend from a side of the trailer.
 11. The method of claim 10,further comprising: mounting a pair of rail assemblies to opposing sidesof a foundation; and after (q), guiding gantry onto the pair of railassemblies.